JP3447166B2 - Hot water mat for floor heating and method of manufacturing the same - Google Patents

Description

Detailed Description of the Invention

[0001]

The present invention relates to relates to a method of manufacturing a hot water mat and its use in floor heating to heat the room from the floor. Particularly, a method for manufacturing a hot water mat and its floor heating that can reduce the manufacturing cost of the mat.

[0002]

2. Description of the Related Art First, the structure of a conventional hot water mat will be described. Floor heating is a method of heating the room from the floor by flowing warm water (60 ° C., for example) through a radiating pipe in a warm water mat laid under a floorboard (flooring) or tatami mat.
It is popular because it can effectively heat the bottom of the room, which is difficult to heat with ordinary heating, and it is being installed in many homes in recent years. FIG. 5: is a top view which shows the structure of the conventional warm water mat for floor heating. 2 is a schematic cross-sectional view originally showing the structure of the floor heating hot water mat of the present invention.
Since the conventional hot water mat for floor heating has the same cross-sectional structure, it will be described with reference to FIG.

As shown in FIG. 2, a pipe groove 41 is dug in the upper surface of the mat plate 5, which is made of a heat insulating material such as foamed polyethylene and should be called a hot water mat body. The pipe groove 41 has a substantially U-shaped cross section, and the radiating pipe (hot water pipe) 2 is laid therein. Warm water of about 60 ° C. flows in the radiating pipe 2. The upper surface of the radiation pipe 2 is substantially flush with the upper surface of the mat plate 5. The heat dissipation pipe is
It is made of cross-linked polyethylene and has flexibility. The mat plate 5 is cut off in some places, and a small joist 7 is embedded therein. The small joist 7 is a strip-shaped plate made of plywood or the like, and plays both the role of reinforcing the warm water mat and the role of a nailing member.

On the upper surface of the mat plate 5 including the piping groove 41 and the upper surface of the small joist 7, a heat dissipation sheet 6 made of aluminum foil is provided.
Is pasted. The heat dissipation sheet 6 is for transmitting the heat emitted from the hot water in the heat dissipation pipe 2 to the upper surface of the hot water mat and radiating the heat from the hot water mat toward the upper room. The warm water mat 1 is placed on the floor structure of the building (concrete or wooden floor). On the warm water mat 1, floor materials (flooring, tatami,
Carpet) is laid.

Next, the planar structure of the conventional hot water mat will be described with reference to FIG. FIG. 5 shows a state in which the heat dissipation sheet on the upper surface is removed. The warm water mat 101 has
Eight small joists 107 are inserted in the vertical direction of the figure. The Kota 107 at the left end of the figure is the upper side 1 of the warm water mat 101.
The hot water mat 10 extends from 30 in a comb-like shape downward in the drawing.
It reaches near the bottom edge 131 of 1. The second joist 107 from the left extends upward from the lower side 131 and extends to the upper side 13.
It has reached close to zero. In this way, the small joists are arranged like two interdigitated comb teeth.

Small joist 107 on the surface of the warm water mat 101
The mat plate 103 is present in the other portions, and the heat radiation pipes 102 are laid in a loop on the mat plate 103. That is, in the left half of the warm water mat 101,
From the hot water inlet header 119 arranged at the center of the upper side 130 of the warm water mat 101, two heat radiating pipes 102a emerge and extend between the small joists 107 in the direction of the lower side 131.
7 goes to the left on the pipe crossing 113 between the tip 108 of the mat and the bottom side 131 of the mat, further rises and descends between the small joists 107, descends to the left side of the leftmost small joist 107, and rises to the hot water mat. It reaches the turn-back portion 123 at the upper left corner of 101, and makes a U-turn here, goes down near the left side 132 of the mat, then goes right on the pipe crossing path 113, and then ascends and descends like sewing the joist 107. , Rises and enters the outlet header 121 (radiation pipe 102b).

The inlet header 119 has two inlet side heat radiation pipes 102 for supplying hot water supplied from the hot water inlet pipe 115.
Distribute to a. The outlet header 121 collectively sends the hot water from the two radiation pipes 102b on the outlet side to the hot water outlet pipe 117. The portion of the heat radiating pipe 102 that is laid along the longitudinal direction of the small joists 107 is called a vertical portion, and the tip 108 of the small joists 107 and the upper and lower sides 13 of the mat.
A portion laid on the crossroad 113 between 0 and 131 is called a transverse portion.

An example of specifications of the conventional hot water mat of FIG. 5 is shown below. Overall mat dimensions: width 2,680 mm, height 1,770 m
m, thickness 12 mm Mat plate: expanded polyethylene, thickness 12 mm Effective heat dissipation area: 4.74 m ² Radiator pipe: cross-linked polyethylene pipe, outer diameter 7.2 mm, wall thickness 1.
1mm, total length 68m Small joist: plywood, width 45mm, thickness 12mm

The mat plate 103 of the warm water mat shown in FIG. 5 is conventionally a single piece. That is, the mat board 103 was connected as a whole, although there was an elongated cut from the upper side 130 and the lower side 131 toward the center in the part where the small joist 107 was inserted. Then, the pipe groove processing of the mat plate 103 is performed by a processing machine called a router (corresponding to a plano mirror in cutting processing) capable of moving a resin melting tool (corresponding to an end mill in cutting processing) three-dimensionally. That is, a large piece of expanded polyethylene (or expanded polystyrene) plate is placed on the table of the router, the resin melting tool is pushed into the plate to the depth of the pipe groove, and the tool (or The table) was moved to process the pipe groove.

[0010]

The above-mentioned conventional manufacturing method has the following problems. Due to the large size of the mat plate (maximum 3.3m x 2.
4m), it was necessary to install a router with a table corresponding to it in the factory, which required a large amount of capital investment. Since each pipe groove is processed by a router, the production efficiency was poor and the processing cost was high. In some cases, a material that fits the dimensions of the mat plate may not be obtained, so the material yield was poor when mill ends were left.

[0011] The present invention is, floor heating that can reduce the manufacturing cost
An object is to provide a hot water mat for use and a method for producing the same.

[0012]

In order to solve the above problems, a hot water mat for floor heating according to the present invention is made of a heat insulating material, and has a mat having a loop-shaped pipe groove on the upper surface and a pipe groove of this mat. The laid hot water pipe (radiation pipe),
A hot water mat for floor heating, comprising: a heat dissipation sheet made of a good heat conductive material, which is attached to the upper surface of the mat; and the mat has a plurality of pipe grooves arranged in parallel in a straight line. It is made by dividing it into the part (vertical part mat plate) and the other part (horizontal part mat plate), combining each part mat plate and laying a radiating pipe on it, mat plate And the whole is integrated by pasting a heat dissipation sheet on the heat dissipation pipe, and further, the small joist which is a strip-shaped plate embedded in places of the above-mentioned mat and the traverse mat plate including the pipe crossing path. , Between the outer side of the pipe crossing and the upper side or the lower side of the mat board, and a small joist that is arranged so as to be on the extension line of the small joist, and the longitudinal mat boards are mutually, It is divided by small joists and The transverse portions mat plate comprising a pipe cross passage, cuts the tip of the small joists,
And, the cuts for the small koto are formed , and
The mat board and the small joist can be attached to the upper surface of the mat.
It is characterized in that it is integrally formed as a whole by the heat sheet . The method for producing a warm water mat for floor heating according to the present invention,
A mat made of a heat insulating material and having a loop-shaped piping groove on the upper surface, hot water piping (radiation pipe) laid in the piping groove of this mat, and a good heat conducting material attached to the upper surface of the mat A heat-dissipating sheet comprising: a heat-dissipating sheet; and a mat in which a plurality of pipe grooves are arranged in parallel in a straight line (vertical mat plate). , It is divided into other parts (transverse part mat plate) to make, combine each part mat plate and lay a heat radiating pipe on it, and then attach the heat radiating sheet on the mat plate and the radiant pipe. Integrate the whole,
At that time, a small joist is placed between the notches for the tip of the joists provided on the traverse mat plate including the pipe crossing and the divided longitudinal mat plates, and Between the outside of the pipe crossing and the upper or lower side of the mat plate, place the small kota in the notch provided so as to be on the extension line of the above small joist, and place the mat plate and the small joist of each part.
And throughout the heat radiation sheet that adhered to the mat upper surface
The feature is that it is a one-piece product .

[0013] By dividing what portion of mat board mat, machining mat plate (or forming) machine can be reduced in size. In addition, the mat plate in the portion where only the parallel linear grooves are present can be produced by extruding the final product in one shot or grooving at once with a router having multiple tools, so that the production efficiency is improved. In the latter case of multi-tool router processing, the groove does not necessarily have to be a straight line.

[0014]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, a more specific description will be given with reference to the drawings. First, the structure of a floor heating hot water mat suitable for realizing the manufacturing method of the present invention will be described. FIG. 1 is a plan view showing the structure of a floor heating hot water mat according to one embodiment of the present invention. FIG. 2 is a sectional view schematically showing the sectional structure of the hot water mat shown in FIG. Figure 1
Is a state in which the mat before the heat dissipation sheet is pasted is viewed from above.

The basic cross-sectional structure shown in FIG. 2 is
Qualitatively the same as the conventional hot water mat. However, the size of the heat radiation pipe is larger (10 mm) than the conventional outer diameter of 7.2 mm.

Next, the planar structure of the hot water mat of this embodiment will be described with reference to FIG. The warm water mat 1 of FIG. 1 also
Similar to the conventional warm water mat shown in FIG. 5, eight small joists 7 are arranged so as to extend in the vertical direction. The pitch of adjacent Kota 7 is 303 mm, which is the same as the conventional warm water mat. However, the planar shape of the small joist 7 is different from that of the warm water mat shown in FIG. That is, the warm water mat 1 of FIG. 1 has two types of small joists (both ends cross path type small joists 7a and one end crossing type small joists 7b) having different shapes. For example, the leftmost end of the small joist 7a has both ends 23 and 25 remaining in the mat plate and does not reach the upper side 19 or the lower side 21 of the mat. Then, the upper and lower end portions 23 of both small joists,
25 and the upper and lower sides 19, 21 between the pipe crossing path 13
There is a and Ko Kota 9.

The pipe crossing path 13a at the upper left corner is a portion where the mat plate (transverse part mat plate 3a) remains, and one heat radiating pipe 2 passes through the central portion thereof. Small Kota 9
Is a small joist having a short length (40 mm in one example). Small kota 9 is located outside the pipe crossing 13a and on the upper side 19 or the lower side 21.
It is arranged so as to be on the extension line of the small joist 7a between the and. Small Kota 9 is the upper side 19 and the lower side 2 of the mat 1.
No. 1 is also installed from the viewpoint of needing a nailable portion.

Near the pipe crossing 13a (on the left or right side)
Auxiliary Koneta 11 is installed in. Auxiliary Kota 1
No. 1 has the same thickness and width as Komoji 7 and Komoji 9 (12m
m, 45 mm) and the length is 175 mm as an example, and is provided so as to extend from the upper and lower sides 19, 21 of the mat in parallel to the joist 7 and inside the mat. The main purpose of the auxiliary joist 11 is to reinforce the pressure resistance of the portion of the pipe crossing path 13a. That is, when the flooring material is placed on the pipe crossing path 13a in the lateral direction in the figure, a plate material that supports the flooring material is required in the mat 1. In particular, in the upper left of the first row, the second row, and the third row of the small joists 7, three rows are continuously provided in the lateral direction, and pipe crossing paths 13a, 13b,
Since there is 13a, if the auxiliary joist 11 is not present, the load applied to the flooring material which comes on the pipe crossing in the three rows will be applied to the heat radiating pipe 2 and there is a risk of deformation (sinking of the floor). come.

The second small joist 7b from the left of the warm water mat shown in FIG. 1 is a single end cross path type small joist. That is, the lower side of the small joists 7b does not reach the lower side 21 of the mat and there is no pipe crossing path, and the upper side does not reach the upper side 19, and the end of the small joist end 27 is connected to the piping cross way 13b and the small kota 9 Exists. These roles are the same as in the case of the leftmost small joist 7a. Two heat radiating pipes pass through the pipe crossing path 13b. The third small joist 7a from the left is again a double-ended crossroads type, and the fourth small joist 7b is a single-ended crossroads type. Thereafter, both ends of the crossroads type kota 7a and one end of the crossroads type kota 7b are alternately arranged toward the right.

The mat of the hot water mat 1 of FIG. 1 is divided into a large number of blocks. First, as a vertical division, a line connecting the inner ends of the auxiliary joists 11 on the upper side and the lower side (mat plate cut 4) is used to form a longitudinal mat plate 5 at the center and a transverse mat plate 3 at both ends. It is divided. Further, the vertical mat plate 5 is divided in the left-right direction by a small joist 7. Further, the transverse part mat plate 3 is divided in the left-right direction by the auxiliary joist 11 and the joist 7.
The reason for being divided in this way is mainly from the viewpoint of manufacturing rationalization, in which the pipe groove processing efficiency of the mat plate is improved. In addition, the mat plate and the joist of each part are integrally formed as a whole by a heat dissipation sheet (6 in FIG. 2) attached to the upper surface of the mat.

[0021] FIGS. 3 and 4 for each block of the mat
It will be specifically described with reference to. FIG. 3 is a plan view showing the planar shapes of various transverse mat plates used in the floor heating hot water mat of FIG. 1. FIG. 4 is a plan view showing a planar shape of a longitudinal mat plate used in the floor heating hot water mat of FIG. 1. The transverse part mat plate 3a shown in FIG. 3 (a) is a mat plate of a type including a pipe crossing path 13a of one groove. In the warm water mat 1 shown in FIG.
Used in various places. The transverse mat plate 3a having different left and right sides is the transverse mat plate 3a ', and is used in the hot water mat 1 of FIG. 1 at four places such as the third from the left on the upper side. In FIG. 3, reference numeral 51 is a cut for a small joist, and reference numeral 53 is a cut for a tip portion of a small joist.

The transverse part mat plate 3b shown in FIG. 3 (b) is a mat plate of a type including a pipe crossing path 13b having two grooves. In the hot water mat 1 of FIG. 1, it is used at three places such as the second from the left on the upper side. The transverse part mat plate 3e shown in FIG. 3 (e) is a type in which the transverse part mat plate 3b has a slightly wider width. In the hot water mat 1 of FIG.
It is used in the lower right corner. The transverse part mat plate 3c shown in FIG. 3 (c) is used at the upper right corner of the hot water mat 1 in FIG. The transverse part mat plate 3d shown in FIG. 3 (d) is a type including the U-turn part 31 of the heat radiating pipe, and is used in the lower left corner of the hot water mat 1 in FIG.

As shown in FIG. 4, there are only two types of the longitudinal mat plate 5. That is, there are a vertical portion mat plate 5a having three pipe grooves 41 extending vertically in a straight line and a vertical portion mat plate 5b having two pipe grooves 41. In the hot water mat shown in FIG. 1, eight longitudinal mat plates 5a are arranged from the left end to the right.
Is used, and only the rightmost one sheet is the vertical section mat plate 5b. In all of these longitudinal mat plates 5, the pipe grooves 41 are straight and parallel, so that groove processing is easy.
For example, even if extrusion of foamed resin or melting processing using a router is performed, it is possible to efficiently form the three piping grooves 41 by providing three router heads at a certain pitch and making one pass of the head. Can be processed.

The arrangement of the radiation pipes in the floor heating hot water mat shown in FIG. 1 will be described. An inlet 15 and an outlet 17 of hot water are provided in the upper right corner of the radiating pipe 2 of the hot water mat 1 shown in FIG. The heat radiating pipe 2a extends from the inlet 15, and meanders up and down like sewing between the small joists 7 to reach the U-turn portion 31 at the lower left corner of the mat, and from there, returns to the heat radiating pipe 2b and similarly becomes at the upper right corner of the mat. Return to exit 17. Specifically, the outgoing radiation pipe 2 started from the upper right corner
a is the lower side 2 of the mat parallel to the small joists 7b in the downward direction of the figure.
Proceed to the vicinity of 1 (this portion is referred to as a vertical portion 33), turn 90 ° leftward at the transverse mat plate 3e, and pass laterally through the pipe crossing path 13b (this portion is referred to as a transverse portion 35). Then, go up in the vertical mat plate 5a, make a U-turn at the horizontal mat plate 3a ', go down along the Koneta 7a (second from right), and at the horizontal mat plate 3a'. Turn to the left through the pipe crossing 13a. Then, it goes up along the third joist 7b from the right and makes a U-turn at the pipe crossing path 13b of the transverse mat plate 3b, and goes down along the joist 7b. After that, proceed in the same manner.

Next, details of the method of manufacturing the mat will be described. (1) Welding method: For the parallel groove mat plate, this welding method has the highest production efficiency. That is, polyethylene (or polystyrene) forming the side wall of the groove
The plurality of rod-shaped members are attached by welding onto a thin sheet (made of the same material) that constitutes the bottom of the groove. In addition, the rod-shaped member is produced by slitting a plate formed by extrusion. Also, at the time of welding, the rod-shaped member and the sheet can be simultaneously extruded and molded. An example of the specifications of extrusion processing is as follows. Extrusion temperature: 170 ℃ Extrusion speed: 3m / sec

(2) Simultaneous multi-groove processing method (router): Polyethylene foam (or polystyrene foam) is partially melted by a plurality of heated router heads to simultaneously machine a plurality of rows of grooves. At this time, the plate of the material is fixed on a vacuum (decompression) chuck table and fed in the longitudinal direction of the groove. The specifications are as follows. Head temperature: 200-300 ° C Table feed speed: 1-2 m / sec

(3) Machining: This is a method of scraping the groove with an end mill or grinder instead of the router. The specifications are as follows. Cutting edge rotation speed: 5,000-6,000 rpm Table feed speed: 1-2 m / sec

(4) In-mold foam molding method: This is a method capable of efficiently manufacturing a curved groove mat plate. Molten polyethylene (or polystyrene) containing a foaming agent is injected and cooled in a mold cavity having the shape of a mat plate with curved grooves to perform one-shot molding. The specifications are as follows. Mold temperature: 130-140 ° C

(5) Branding type stamping method: This method is also used for the groove processing of the curved groove mat plate. This is a method of pressing a mold having a groove in the shape of a pipe groove against the surface of a foamed polyethylene flat plate, and processing a notch for a radius or a small joist in one shot. This is one of the methods that can be used, although the groove cross-sectional shape tends to be slightly sharp.

[0030]

As apparent from the above description, the manufacturing method of the floor heating hot water mat and its of the present invention exhibits the following effects. Since the size of the mat plate to be manufactured or processed is small, the manufacturing equipment can be small.
By making each part have a standard shape, hot water mats of various shapes and sizes can be manufactured as a combination of standard parts. Shapes that are easy to manufacture (eg straight parallel grooves)
It can be divided into two parts, and a highly efficient production method suitable for the shape can be taken. As a result, the manufacturing cost of the mat plate of the warm water mat can be reduced. Since the mat is divided, the pitch of the joist (example 303 mm) can be accurately defined. In the case of a wide one-piece mat, the mat may be deformed during the processing of the router, but the mat of the present invention does not cause such deformation, and the accuracy of the outer dimension is improved.
By changing the length of the straight groove part, it is possible to support the production of mats of various sizes.

[Brief description of drawings]

FIG. 1 is a plan view showing the structure of a floor heating hot water mat according to an embodiment of the present invention.

FIG. 2 is a sectional view schematically showing a sectional structure of the hot water mat shown in FIG.

3 is a plan view showing the planar shape of various transverse mat plates used in the floor heating hot water mat of FIG. 1. FIG.

FIG. 4 is a plan view showing a planar shape of a longitudinal mat plate used in the floor heating hot water mat shown in FIG. 1;

FIG. 5 is a plan view showing the structure of a conventional hot water mat for floor heating.

[Explanation of symbols]

1 Hot Water Mat 2 Hot Water Pipe (Radiation Pipe) 3 Traverse Mat Plate 4 Mat Board Break 5 Vertical Mat Board 6 Heat Dissipating Sheet 7 Koneta 9 Kokoneta 11 Auxiliary Koneta 13 Pipe Crossing 15 Hot Water Inlet 17 Hot Water Outlet 19 Upper side 21 Lower side 23, 25, 27 Kodota end 31 U-turn section 33 Vertical section 35 Traverse section 41 Piping groove 51 Cutout for small joist 53 Cut for small joist 101 Hot water mat 102 Radiating pipe 103 Mat plate 107 Small joist 108 Kodota tip 113 Pipe crossing path 115 Hot water inlet pipe 117 Hot water outlet pipe 119 Inlet header 121 Outlet header 123 Folding part 130 Mat upper side 131 Mat lower side 132 Mat left side 133 Mat right side

Continuation of front page (56) Reference JP-A-7-324758 (JP, A) JP-A-7-293923 (JP, A) JP-A-7-2698885 (JP, A) JP-A-8-159497 (JP , A) JP 9-53834 (JP, A) JP 8-233293 (JP, A) JP 8-270968 (JP, A) JP 8-273969 (JP, A) JP 9-119656 (JP, A) Actually open 3-52510 (JP, U) Actually open 6-40718 (JP, U) Special table 9-511323 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) F24D 3/16

Claims (4)

(57) [Claims] 1. A mat made of a heat insulating material, having a loop-shaped pipe groove on the upper surface, a hot water pipe (radiating pipe) laid in the pipe groove of the mat, and a mat attached to the upper surface of the mat, A warm water mat for floor heating, comprising: a heat-dissipating sheet made of a good heat-conducting material; in the mat, a portion in which several pipe grooves are arranged in parallel in a straight line (vertical mat plate). ) And the other part (transverse part mat plate) are made separately, and each part mat plate is combined and a heat dissipation pipe is laid on it.
The whole is integrated by pasting a heat dissipation sheet on the mat plate and the heat dissipation pipe, and further, a strip-shaped plate is embedded in various places of the above mat, and a traverse part mat including a pipe crossing path. Between the outside of the pipe crossing and the mat plate top side or bottom side, there is a small joist that is arranged so as to be on the extension line of the above small joist, and is divided by the small joists, in transverse section the mat plate containing the pipe cross path, cuts the tip of the small joists, and are the small small joists for notch formation, each unit of the mat plate And Koneta is attached to the top of the mat.
A warm water mat for floor heating, characterized by being integrated as a whole with a heat dissipation sheet . 2. A curved groove of the transverse mat plate
The matte plate of the
(Styrene), having the shape of a mat plate with curved grooves
Molded by injection and cooling in the mold cavity
The hot water mat for floor heating according to claim 1. 3. A mat made of a heat insulating material, having a loop-shaped pipe groove on the upper surface, a hot water pipe (radiating pipe) laid in the pipe groove of the mat, and attached to the upper surface of the mat. A method of manufacturing a hot water mat for floor heating, comprising: a heat dissipation sheet made of a good heat conductive material; a part of the mat having a plurality of pipe grooves arranged in parallel in a straight line (longitudinal direction). Part mat plate) and other parts (transverse part mat plate) are divided into two parts, and each part mat plate is combined and a heat radiation pipe is laid on it. After that, a heat radiation sheet is placed on the mat plate and heat radiation pipe. The whole is integrated by affixing, and at that time, a small joist is placed between the cuts for the tip of the small joist provided on the transverse mat board including the pipe crossing and the divided longitudinal mat boards, Pipe crossing of the mat plate of the traverse section including the pipe crossing Between the outer and the mat plate upper or lower side, placing a small small joists in notches provided to come on the extension of the small joists
Then, attach the mat plate and the joist of each part to the upper surface of the mat.
A method of manufacturing a hot water mat for floor heating, characterized in that it is integrally formed with a heat dissipation sheet . 4. A molten polyethylene (or polyethylene) containing a foaming agent.
(Styrene), having the shape of a mat plate with curved grooves
Injection, cooling in the mold cavity and molding
Manufacture of mat board with curved groove of mat board
The production of a warm water mat for floor heating according to claim 1.
Method.